EDM Electrodes

A process for forming an electrical discharge machining electrode, comprising the steps of:

• (a) dry blending granules of carbon and granules of a refractory selected from the group consisting of tungsten, molybdenum, carbides of either, and stoichiometric and hyperstoichiometric carbides of the other elements of groups IVB, VB, and VIB of the Periodic Table of the Elements, said granules being combined according to the relationship ##EQU9## wherein C is said carbon, R is said refractory, the volume percent terms are the fraction of said electrode occupied by C or R, and the surface area terms are the surface areas in m.sup.2 /g of said carbon or refractory granules measured before said carbon or refractory granules are blended together, thereby forming a uniform mixture;
• (b) warm mixing said granules with up to 62 volume percent of a thermoplastic or thermoset, heat fugitive, organic binder;
• (c) molding the resulting mixture in a heated flexible mold, cooling said mold and its contents to room temperature, and demolding said contents thereby forming an essentially void-free green molded preform having the size and shape of said mold;
• and
• (d) heating said green molded preform to thermally degrade and remove the bulk of said binder, thereby forming a rigid, handleable, skeletal preform;
• (e) placing said preform in contact with an infiltrant comprising copper, silver, or alloys containing copper or silver and heating said preform and said infiltrant above the melting point of said infiltrant at ambient pressure, whereby said infiltrant melts and wicks into the connected porosity of said preform by capillary action, and wherein the volume percent of said carbon, said refractory, and said infiltrant are on or within the boundaries DEFG of FIG. 7;
• and
• (f) cooling the infiltrated part to room temperature.